Dual-motor controller

Abstract

The invention relates to the technical field of electric drive, and discloses a dual-motor controller, which comprises a box body; the number of the driving module assemblies is two; the thin film capacitor is arranged between the two driving module assemblies and electrically connected with the two driving module assemblies; the power distribution module is arranged in the box body and electrically connected with the thin-film capacitor, in the power taking state, the power distribution module outputs current provided by the vehicle battery for the thin-film capacitor to electric equipment, and in the charging state, the power distribution module transmits current of an external power supply to the vehicle battery through the thin-film capacitor; and the EMC filtering assembly is arranged in the box body and electrically connected with the thin-film capacitor, the EMC filtering assembly is provided with a power supply connecting end, and the power supply connecting end is suitable for being connected with a vehicle battery. The internal design of the dual-motor controller realizes the power taking and charging functions of a vehicle battery, the dual-motor controller has the characteristics of multiple functions and high integration, external parts and external high-voltage wiring harnesses are saved, the space and the cost are saved, and the requirements of integration and light weight of a new energy vehicle are met.

Description

Technical Field

[0001] The present invention relates to the field of electric drive technology, and in particular to a dual-motor controller. Background Art

[0002] As the core component of new energy vehicles, the electric drive system is the key to realize various working modes of new energy vehicles and directly affects the performance of the whole vehicle. In the existing technology, a dual-motor drive system has been introduced to achieve high performance and high output capacity to meet the market demand for new energy vehicles. In order to reduce the space occupied by the whole vehicle, a dual-motor controller is used to control the two motors. However, the existing dual-motor controller has a single function and needs to cooperate with other components on the vehicle to realize functional diversification, resulting in a complex number of components and connecting wiring harnesses, and a low degree of integration. Summary of the invention

[0003] In view of this, the present invention provides a dual-motor controller to solve the problem that the existing dual-motor controller has a single function and needs to cooperate with other components on the vehicle to achieve diversified functions, resulting in a complex number of components and connecting wiring harnesses and a low degree of integration.

[0004] The present invention provides a dual-motor controller, comprising: a housing; two drive module assemblies, which are arranged side by side in the housing along a horizontal direction; a film capacitor, which is arranged between the two drive module assemblies and is electrically connected to both of the drive module assemblies; a power distribution module, which is arranged in the housing and is electrically connected to the film capacitor, the power distribution module having a power-taking state and a charging state, in which the power distribution module outputs the current provided by a vehicle battery to the film capacitor to an electrical device, and in the charging state, the power distribution module transmits the current of an external power supply to the vehicle battery via the film capacitor; an EMC filter assembly, which is arranged in the housing and is electrically connected to the film capacitor, the EMC filter assembly having a power connection end, and the power connection end is suitable for connecting to a vehicle battery.

[0005] Beneficial effects: Two drive module components are used to realize the drive control of two motors, and the current of the vehicle battery flows through the EMC filter component and is transmitted to the thin film capacitor. The thin film capacitor divides the current to the two drive module components and the three loads of the distribution module, so that the distribution module can draw power to supply power to external power-consuming equipment. In the charging stage, the current of the external power supply flows through the distribution module, the thin film capacitor and the EMC filter component and is transmitted to the vehicle battery to realize the charging function of the vehicle battery. With such a setting, the internal design of the dual-motor controller realizes the power drawing and charging functions of the vehicle battery, has the characteristics of multi-function and high integration, saves external components and external high-voltage wiring harnesses, saves space and cost, and meets the requirements of integration and lightweight of new energy vehicles.

[0006] In an optional embodiment, the thin film capacitor includes a capacitor body, a first busbar assembly, a second busbar assembly and a third busbar assembly, the first busbar assembly, the second busbar assembly and the third busbar assembly are all electrically connected to the capacitor body, the first busbar assembly is electrically connected to the EMC filter assembly, two second busbar assemblies are provided, the two second busbar assemblies are electrically connected to the two drive module assemblies respectively, and the third busbar assembly is electrically connected to the power distribution module.

[0007] Beneficial effect: The current of the vehicle battery flows through the EMC filter component and is transmitted to the capacitor body through the first busbar component. The two second busbar components and the third busbar component then divert the current to the two drive module components and the distribution module to realize power supply to the load.

[0008] In an optional embodiment, a cooling channel is formed in the bottom plate of the box body, and a liquid inlet and a liquid outlet are opened on the box body. The liquid inlet and the liquid outlet pass through the box body and are respectively connected to the two ends of the cooling channel. The two driving module components and the thin film capacitor are all arranged on the bottom plate and corresponding to the cooling channel.

[0009] Beneficial effects: The coolant flows into the cooling channel from the liquid inlet, flows through the two drive module components and the film capacitor through the cooling channel, and then flows out from the liquid outlet, thereby achieving heat dissipation of the two drive module components and the film capacitor, ensuring good heat dissipation and cooling effects on the drive module components and the film capacitor under high load and high loss conditions. In addition, the two drive module components and the film capacitor are laid flat on the bottom plate, and the cooling channel is set in the bottom plate, which can save longitudinal space, reserve more space for the vehicle cabin, and is conducive to the flexible arrangement of the vehicle space.

[0010] In an optional embodiment, the box body also includes a surrounding plate, which is connected to the bottom plate and is circumferentially arranged around the bottom plate, and a first shielding plate is protruded from the bottom plate, and the first shielding plate encloses a first shielding space, or the first shielding plate and the surrounding plate enclose a first shielding space; the EMC filter assembly is arranged in the first shielding space, and the dual motor controller also includes an EMC shielding plate, which is arranged above the EMC filter assembly and closes the first shielding space.

[0011] Beneficial effect: The first shielding plate and the EMC shielding plate are used to achieve high and low voltage signal shielding between the EMC filter component and the control circuit board.

[0012] In an optional embodiment, a second shielding plate is protruded from the bottom plate, and the second shielding plate encloses a second shielding space, or the second shielding plate and the enclosure plate enclose a second shielding space; the dual-motor controller also includes a control circuit board and a low-voltage signal connector, and the low-voltage signal connector is arranged on the control circuit board and electrically connected to the control circuit board; the control circuit board is stacked on top of the EMC shielding plate, and the portion of the low-voltage signal connector protruding from the lower surface of the control circuit board is located in the second shielding space, and the control circuit board encloses the second shielding space.

[0013] Beneficial effect: A closed space is formed by utilizing the second shielding plate and the control circuit board to achieve shielding of the low-voltage signal connector.

[0014] In an optional embodiment, the driving module assembly includes a driving circuit board and a SIC module, the driving circuit board is electrically connected to the SIC module, the SIC module is arranged above the base plate, the driving circuit board is arranged above the SIC module, and the control circuit board and the driving circuit board are arranged flat in the same horizontal plane.

[0015] Beneficial effects: The drive module components, thin film capacitors and EMC filter components are laid flat in the box, and the control circuit board and the EMC filter components are stacked. The control circuit board and the drive circuit board are laid flat, which can shorten the longitudinal height. Not only is the dual-motor controller space utilization rate high, but the space between the dual-motor controller and the dual motors can be better utilized. It has the advantages of high integration and high space utilization, provides a larger layout space for the vehicle, is conducive to the flexible layout of the entire vehicle, reserves more space for the cabin, and enhances the passenger experience.

[0016] In an optional embodiment, the EMC filter component includes: a multi-stage filter sub-circuit connected in series, each of the filter sub-circuit includes: an LC filter circuit, a plurality of first RC filter circuits and a plurality of second RC filter circuits, wherein the first end of each of the first RC filter circuits is connected to the first end of the LC filter circuit, the second end of each of the first RC filter circuits is connected to the first end of each of the second RC filter circuits, and the second end of each of the second RC filter circuits is connected to the second end of the LC filter circuit; the LC filter circuit includes a magnetic ring and an X capacitor connected in parallel; the first RC filter circuit and the second RC filter circuit both include a resistor and a Y capacitor combination connected in series.

[0017] Beneficial effects: The LC filter circuit and the RC filter circuit perform differential mode filtering and common mode filtering respectively, and the use of multi-stage series-connected filter subcircuits can achieve multi-stage filtering, thereby improving the accuracy of the input signal.

[0018] In an optional embodiment, the EMC filter component further includes a bus and an interface circuit board, the multi-stage X capacitors and the multi-stage Y capacitors are both connected to the interface circuit board, the bus passes through the multi-stage magnetic rings in sequence, one end of the bus forms the power connection end, the other end of the bus is electrically connected to the film capacitor, the bus is connected to the interface circuit board through a copper bus between two adjacent stages of the magnetic rings, and is connected to a corresponding combination of one of the X capacitors and one of the Y capacitors through the interface circuit board.

[0019] Beneficial effects: The integrated design using a combination of multi-stage magnetic rings, multi-stage X capacitors and multi-stage Y capacitors can achieve multi-stage filtering, thereby achieving good electromagnetic compatibility performance.

[0020] In an optional embodiment, at least one of the multiple levels of magnetic rings is a nanocrystalline magnetic ring, and at least one of the multiple levels of magnetic rings is a ferrite magnetic ring.

[0021] Beneficial effect: Using magnetic rings of different materials can achieve better magnetic properties and meet the use requirements of the dual-motor controller under different working conditions.

[0022] In an optional implementation, the dual-motor controller further includes a low-voltage shielding cover, which is connected to the upper surface of the control circuit board and covers the low-voltage signal connector. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0024] Figure 1 A schematic diagram of the decomposed structure of a dual-motor controller according to an embodiment of the present invention;

[0025] Figure 2 A schematic diagram of the structure of an EMC filter assembly according to an embodiment of the present invention;

[0026] Figure 3 for Figure 2 The schematic diagram of the decomposed structure of the EMC filter component shown;

[0027] Figure 4 for Figure 3 A schematic diagram of the structure of the middle interface circuit board, X capacitor and Y capacitor combination from another angle;

[0028] Figure 5 A circuit diagram of an EMC filter assembly according to an embodiment of the present invention;

[0029] Figure 6 A schematic diagram of the structure of a film capacitor and a power distribution module according to an embodiment of the present invention;

[0030] Figure 7 A top view of a thin film capacitor according to an embodiment of the present invention;

[0031] Figure 8 It is a structural schematic diagram of a driving module assembly according to an embodiment of the present invention;

[0032] Fig. 9 for Figure 8 The schematic diagram of the exploded structure of the drive module assembly shown;

[0033] Fig.10 It is a schematic structural diagram of a control circuit board, a low-voltage signal connector and a low-voltage shielding cover according to an embodiment of the present invention;

[0034] Fig.11 A schematic diagram of the internal structure of a housing according to an embodiment of the present invention;

[0035] Fig.12 for Fig.11 A bottom view of the housing is shown.

[0036] Description of reference numerals:

[0037] 1. Box body; 11. Bottom plate; 111. Heat sink; 112. Sealing groove; 12. Liquid inlet; 13. Liquid outlet; 14. Enclosure; 15. First shielding plate; 16. Second shielding plate; 17. Shell; 18. Cover plate; 19. ODP interface; 2. Drive module assembly; 21. Drive circuit board; 22. SIC module; 23. Three-phase current sensor; 24. Three-phase bus assembly; 241. Three-phase bus body; 242. Bracket; 3. Thin Membrane capacitor; 31. Capacitor body; 32. First busbar assembly; 33. Second busbar assembly; 34. Third busbar assembly; 4. Power distribution module; 5. EMC filter assembly; 51. Magnetic ring; 52. X capacitor; 53. Y capacitor combination; 54. Bus; 541. Input bus; 542. Output bus; 55. Interface circuit board; 56. Terminal block; 6. EMC shielding plate; 7. Control circuit board; 8. Low-voltage signal connector; 9. Low-voltage shielding cover. DETAILED DESCRIPTION

[0038] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0039] The traditional dual-motor drive system uses two independent drive units, that is, the two motors are controlled and driven by two independent controllers. This design wastes a lot of chassis space and is contrary to the requirements of vehicle integration and lightweight. In addition, the two independent controllers require two sets of controller components, as well as the components and wiring harnesses connected to the controllers. From a cost perspective, the manufacturing cost is greatly increased. With the development, the dual-motor drive system has gradually developed into a dual-motor sharing one controller (also known as a dual-motor controller), and the two drive module components share one film capacitor. Although it can reduce the use of components and wiring harnesses to a certain extent, the dual-motor controller has a relatively single function, and there are still many components and connecting wiring harnesses used in conjunction with the dual-motor controller, and the degree of integration is low.

[0040] Combine the following Figures 1 to 12 , describing an embodiment of the present invention.

[0041] According to an embodiment of the present invention, a dual-motor controller is provided, comprising: a housing 1, a drive module assembly 2, a film capacitor 3, a power distribution module 4 and an EMC filter assembly 5. Two drive module assemblies 2 are provided, and the two drive module assemblies 2 are arranged side by side in the housing 1 along the horizontal direction. The film capacitor 3 is arranged between the two drive module assemblies 2 and is electrically connected to both drive module assemblies 2. The power distribution module 4 is arranged in the housing 1 and is electrically connected to the film capacitor 3. The power distribution module 4 has a power-taking state and a charging state. In the power-taking state, the power distribution module 4 outputs the current provided by the vehicle battery to the film capacitor 3 to the electrical equipment. In the charging state, the power distribution module 4 transmits the current of the external power supply to the vehicle battery through the film capacitor 3. The EMC filter assembly 5 is arranged in the housing 1 and is electrically connected to the film capacitor 3. The EMC filter assembly 5 has a power connection terminal, and the power connection terminal is suitable for connecting the vehicle battery.

[0042] Two drive module components 2 are used to realize the drive control of two motors, and the current of the vehicle battery flows through the EMC filter component 5 and is transmitted to the film capacitor 3. The film capacitor 3 divides the current to the three loads of the two drive module components 2 and the distribution module 4, so that the distribution module 4 draws power to supply power to external power-consuming equipment. In the charging stage, the current of the external power supply flows through the distribution module 4, the film capacitor 3 and the EMC filter component 5 and is then transmitted to the vehicle battery, realizing the charging function of the vehicle battery. With such a configuration, the internal design of the dual-motor controller realizes the power drawing and charging functions of the vehicle battery, has the characteristics of multi-function and high integration, saves external components and external high-voltage wiring harnesses, saves space and cost, and meets the requirements of integration and lightweight of new energy vehicles.

[0043] Furthermore, the power distribution module 4 is an ODP module (integrated vehicle power management module). Fig.11 and Fig.12 As shown, the housing 1 includes an ODP interface 19 , and external electrical equipment is connected to the ODP module via the ODP interface 19 .

[0044] It is worth noting that the dual motor controller of this embodiment has an internal integrated shunt circuit, and the dual motor controller integrates the power supply and charging functions of the ODP module. In the power supply state, the film capacitor 3 uses a single-phase input and a three-phase load output to realize the shunt function of the bus current delivered by the vehicle battery to the dual motor controller.

[0045] In one embodiment, Figure 7 As shown, the film capacitor 3 includes a capacitor body 31, a first busbar assembly 32, a second busbar assembly 33 and a third busbar assembly 34. The first busbar assembly 32, the second busbar assembly 33 and the third busbar assembly 34 are all electrically connected to the capacitor body 31. The first busbar assembly 32 is electrically connected to the EMC filter assembly 5. Two second busbar assemblies 33 are provided. The two second busbar assemblies 33 are electrically connected to the two drive module assemblies 2 respectively, and the third busbar assembly 34 is electrically connected to the power distribution module 4. In this way, the current of the vehicle battery flows through the EMC filter assembly 5 and is delivered to the capacitor body 31 through the first busbar assembly 32. The two second busbar assemblies 33 and the third busbar assembly 34 then shunt the current to the two drive module assemblies 2 and the power distribution module 4 to realize power supply to the load.

[0046] Further, such as Figure 7 As shown, the capacitor body 31 is a square structure, the first busbar assembly 32 and the third busbar assembly 34 are arranged on two opposite sides of the capacitor body 31, and the two second busbar assemblies 33 are arranged on the other two opposite sides of the capacitor body 31.

[0047] It is worth noting that each busbar assembly includes a number of connection terminals.

[0048] In one embodiment, Fig.11 and Fig.12 As shown, a cooling channel is formed in the bottom plate 11 of the box body 1, and a liquid inlet 12 and a liquid outlet 13 are provided on the box body 1. The liquid inlet 12 and the liquid outlet 13 are set through the box body 1 and are respectively connected to the two ends of the cooling channel. The two drive module components 2 and the film capacitor 3 are both arranged on the bottom plate 11 and are arranged corresponding to the cooling channel. The coolant flows into the cooling channel from the liquid inlet 12, flows through the two drive module components 2 and the film capacitor 3 through the cooling channel, and then flows out from the liquid outlet 13, so as to achieve heat dissipation of the two drive module components 2 and the film capacitor 3, and ensure that the drive module components 2 and the film capacitor 3 also have good heat dissipation and cooling effects under high load and high loss conditions. In addition, the two drive module components 2 and the film capacitor 3 are laid flat on the bottom plate 11, and the cooling channel is arranged in the bottom plate 11, which can save longitudinal space, reserve more space for the vehicle cabin, and is conducive to the flexible arrangement of the vehicle space.

[0049] Further, such as Fig.11 and Fig.12 As shown, the cooling channel includes two heat dissipation grooves 111 and a U-shaped loop. The two heat dissipation grooves 111 are respectively connected to the two ends of the U-shaped loop. The two heat dissipation grooves 111 correspond to the two driving module components 2 respectively, and the U-shaped loop corresponds to the film capacitor 3.

[0050] It is worth noting that the two drive module assemblies 2 share a film capacitor 3, which also puts forward greater requirements for the cooling and heat dissipation of the film capacitor 3. In order to meet the heat dissipation requirements of the two drive module assemblies 2 and the film capacitor 3 at the same time, in the related art, the two drive module assemblies 2 and the film capacitor 3 are usually distributed on the upper and lower surfaces of the heat dissipation structure, that is, a stacked arrangement. Although the lateral length of the dual-motor controller is reduced, the influence of the excessive longitudinal height of the dual-motor controller on the layout of the whole vehicle is ignored.

[0051] In one embodiment, Figure 1 and Fig.11 As shown, the box body 1 also includes a panel 14, which is connected to the bottom plate 11 and is circumferentially arranged around the bottom plate 11. A first shielding plate 15 is protruded from the bottom plate 11, and the first shielding plate 15 encloses a first shielding space or the first shielding plate 15 and the panel 14 enclose a first shielding space; the EMC filter assembly 5 is arranged in the first shielding space, and the dual motor controller also includes an EMC shielding plate 6, which is arranged above the EMC filter assembly and closes the first shielding space. In this arrangement, the high and low voltage signal shielding between the EMC filter assembly 5 and the control circuit board 7 is achieved by using the first shielding plate 15 and the EMC shielding plate 6.

[0052] Specifically, Figure 1As shown, the box body 1 includes a shell 17 and a cover plate 18. One end of the shell 17 is open. The cover plate 18 is connected to the shell 17 and blocks the opening to form a receiving space. Further, the shell 17 includes the above-mentioned enclosure 14 and bottom plate 11. Furthermore, the cover plate 18 is stamped with a composite material, which can improve the mode of the cover plate 18, thereby improving the overall NVH performance of the dual-motor controller.

[0053] In one embodiment, Figure 1 , Fig.10 and Fig.11 As shown, a second shielding plate 16 is formed protruding from the bottom plate 11, and the second shielding plate 16 encloses a second shielding space or the second shielding plate 16 and the enclosing plate 14 enclose a second shielding space; the dual-motor controller also includes a control circuit board 7 and a low-voltage signal connector 8, and the low-voltage signal connector 8 is arranged on the control circuit board 7 and is electrically connected to the control circuit board 7; the control circuit board 7 is stacked on the top of the EMC shielding plate 6, and the part of the low-voltage signal connector 8 protruding from the lower surface of the control circuit board 7 is located in the second shielding space, and the control circuit board 7 closes the second shielding space. In this way, the second shielding plate 16 and the control circuit board 7 form a closed space to achieve shielding of the low-voltage signal connector 8.

[0054] Further, such as Fig.10 As shown, the low-voltage signal connector 8 is welded on the control circuit board 7, and the dual-motor controller also includes a low-voltage shielding cover 9, which is connected to the upper surface of the control circuit board 7. The low-voltage shielding cover 9 covers the welding point between the signal pin of the low-voltage signal connector 8 and the control circuit board 7, thereby realizing the shielding function of the low-voltage signal connector 8 and improving the overall EMC effect of the dual-motor controller.

[0055] In one embodiment, Figure 8 and Fig. 9 As shown, the drive module assembly 2 includes a drive circuit board 21 and a SIC module 22, the drive circuit board 21 is electrically connected to the SIC module 22, the SIC module 22 is arranged above the bottom plate 11, the drive circuit board 21 is arranged above the SIC module 22, and the control circuit board 7 and the drive circuit board 21 are laid flat in the same horizontal plane. The drive module assembly 2, the film capacitor 3 and the EMC filter assembly 5 are laid flat in the box body 1, and the control circuit board 7 and the EMC filter assembly 5 are stacked and arranged, and the control circuit board 7 and the drive circuit board 21 are laid flat, which can shorten the longitudinal height, not only the dual motor controller has a high space utilization rate, but also the space between the dual motor controller and the dual motors can be better utilized, with the advantages of high integration and high space utilization, providing a larger layout space for the vehicle, which is conducive to the flexible layout of the whole vehicle, reserving more space for the cabin, and improving the passenger experience.

[0056] Specifically, the signal pins of the SIC module 22 are soldered on the driving circuit board 21 .

[0057] Further, such as Figure 8 and Fig. 9 As shown, the drive module assembly 2 also includes a three-phase current sensor 23 and a three-phase bus assembly 24. The three-phase bus assembly 24 includes a U, V, W three-phase bus body 241 and a bracket 242. The three-phase bus body 241 and the bracket 242 are formed into an integrated structure by plastic packaging. The three-phase bus body 241 passes through the three-phase current sensor 23 and is electrically connected to the SIC module 22 to realize the three-phase current collection function.

[0058] It is worth noting that when drawing power, the vehicle battery supplies power to the dual motor controller, the current passes through the EMC filter component 5, and then flows through the film capacitor 3 to be distributed to the three loads of the two drive module components 2 and the distribution module 4, wherein the two drive module components 2 realize the DC conversion function, thereby respectively flowing through the two three-phase bus components 24 to realize the drive control function of the distributed dual motor controller. When charging, the distribution module 4 of the dual motor controller identifies the input current, and the current flows through the film capacitor 3 and the EMC filter component 5, and reversely charges the vehicle battery from the power connection end of the dual motor controller.

[0059] Specifically, Fig.11 As shown, two sealing grooves 112 are also provided on the bottom plate 11 of the box 1, and two three-phase busbar assemblies 24 are provided corresponding to the two sealing grooves 112, which are used to achieve a sealing function between the three-phase busbar assemblies 24 and the box 1. Furthermore, an O-ring is used to seal the integral structure formed by the overmolding and the box 1.

[0060] In one embodiment, Figure 5 As shown, the EMC filter component 5 includes a plurality of filter subcircuits connected in series, each filter subcircuit includes an LC filter circuit, a plurality of first RC filter circuits and a plurality of second RC filter circuits, wherein a first end of each first RC filter circuit is connected to a first end of the LC filter circuit, a second end of each first RC filter circuit is connected to a first end of each second RC filter circuit, and a second end of each second RC filter circuit is connected to a second end of the LC filter circuit; the LC filter circuit includes a magnetic ring 51 and an X capacitor 52 connected in parallel; the first RC filter circuit and the second RC filter circuit both include a resistor and a Y capacitor combination 53 connected in series, that is, the LC filter circuit and the RC filter circuit perform differential mode filtering and common mode filtering respectively.

[0061] Specifically, Figure 5 As shown, Figure 5Only two filtering sub-circuits are shown, that is, the magnetic ring L1, X capacitor CX1, Y capacitor CY1~Y capacitor CY4, resistor R1~resistor R4 constitute a filtering sub-circuit, the magnetic ring L2, X capacitor CX2, Y capacitor CY5~Y capacitor CY8, resistor R5~resistor R8 constitute a filtering sub-circuit, the magnetic ring L1 and X capacitor CX1 constitute an LC filtering circuit, the magnetic ring L2 and X capacitor CX2 constitute an LC filtering circuit, the Y capacitor CY1 and resistor R1 constitute a first RC filtering circuit, the Y capacitor CY2 and resistor R2 constitute a first RC filtering circuit, the Y capacitor CY3 and resistor R3 constitute a second RC filtering circuit, the Y capacitor CY4 and resistor R4 constitute a second RC filtering circuit, the Y capacitor CY5 and resistor R5 constitute a first RC filtering circuit, the Y capacitor CY6 and resistor R6 constitute a first RC filtering circuit, the Y capacitor CY7 and resistor R7 constitute a second RC filtering circuit, and the Y capacitor CY8 and resistor R8 constitute a second RC filtering circuit.

[0062] Specifically, X capacitors and Y capacitors are safety capacitors, which are mainly used in power supply filters to suppress electromagnetic interference. The connection positions and functions of X capacitors and Y capacitors in the circuit are different. X capacitors are mainly used to suppress differential mode interference, while Y capacitors are mainly used to suppress common mode interference.

[0063] It should be noted that Figure 5 Another magnetic ring L3 is also provided in the middle, and the magnetic ring 51 can perform common mode filtering, but the magnetic ring 51 is provided as required and is not limited here.

[0064] In one embodiment, Figures 2 to 4 As shown, the EMC filter component 5 includes a bus 54, a multi-stage magnetic ring 51, a multi-stage X capacitor 52, a multi-stage Y capacitor combination 53 and an interface circuit board 55. The multi-stage X capacitor 52 and the multi-stage Y capacitor combination 53 are both connected to the interface circuit board 55. The bus 54 passes through the multi-stage magnetic ring 51 in sequence. One end of the bus 54 forms a power connection end, and the other end of the bus 54 is electrically connected to the film capacitor 3. The bus 54 is connected to the interface circuit board 55 through a copper bus between two adjacent magnetic rings 51, and is connected to the corresponding one-stage X capacitor 52 and one-stage Y capacitor combination 53 through the interface circuit board 55.

[0065] Specifically, Figures 2 to 4As shown, the multi-stage magnetic ring 51 includes a primary magnetic ring, a secondary magnetic ring and a tertiary magnetic ring, the bus 54 includes an input bus 541 and an output bus 542, the input bus 541 passes through the primary magnetic ring, the secondary magnetic ring and the tertiary magnetic ring in sequence, and then is connected to the output bus 542. The multi-stage X capacitor 52 includes a primary X capacitor and a secondary X capacitor, the multi-stage Y capacitor combination 53 includes a primary Y capacitor combination and a secondary Y capacitor combination, the input bus 541 leads out a copper bar in the middle of the primary magnetic ring and the secondary magnetic ring and is welded on the interface circuit board 55, and the primary X capacitor and the primary Y capacitor combination are connected through the interface circuit board 55, the input bus 541 leads out a copper bar in the middle of the secondary magnetic ring and the tertiary magnetic ring and is welded on the interface circuit board 55, and the secondary X capacitor and the secondary Y capacitor combination are connected through the interface circuit board 55.

[0066] Further, such as Figure 2 and Figure 3 As shown, the EMC filter assembly 5 further includes a wiring base 56 , on which the busbar 54 and the multi-stage magnetic ring 51 are both arranged, and the wiring base 56 is arranged above the interface circuit board 55 .

[0067] It is worth noting that in the related art, the EMC standard of the single motor controller basically meets CLASS 3, while the internal electronic components of the dual motor controller are more integrated, which brings greater challenges to the internal EMC function of the dual motor controller. Therefore, it is necessary to pay more attention to the overall EMC level of the dual motor controller. In this embodiment, a multi-stage magnetic ring 51, a multi-stage X capacitor 52 and a multi-stage Y capacitor combination 53 are used for integrated design, which can achieve multi-stage filtering, thereby achieving good electromagnetic compatibility performance. In addition, through the cooperation of the box body 1, the first shielding plate 15, the second shielding plate 16, the EMC shielding plate 6 and the shielding cover, the shielding effect of the high and low voltage signal interference and the low voltage signal connector 8 signal interference is achieved, so that the EMC standard of the dual motor controller can meet CLASS 4 or above.

[0068] It should be further explained that EMC (electromagnetic compatibility) refers to the ability of electronic products (including electronic equipment and electronic systems) to work normally in an electromagnetic environment without causing unacceptable interference to the surrounding electromagnetic environment. EMC standards are standards formulated to ensure the normal operation and mutual compatibility of electronic products in an electromagnetic environment. EMC standards are divided into three levels: Class 1, Class 2 and Class 3. Class 4 refers to higher requirements that need to be achieved in some special cases. Class 3 EMC standards refer to basic anti-interference tests and measurements of electronic products to ensure that they can work normally in a general electromagnetic environment and do not cause unacceptable interference to other devices. Class 4 EMC standards are higher-level requirements relative to Class 3 standards. When electronic products need to be used in special environments or work in special circumstances such as near close transmission equipment, they need to comply with Class 4 EMC standards. Class 4 standards are more stringent and specific in test methods and test requirements than Class 3 standards. Level 4 standards usually involve stronger electromagnetic field interference, and put forward higher requirements for the operation stability and anti-interference ability of electronic products to ensure their normal operation in special environments and compatibility with other devices. It should be noted that EMC standards are specifications formulated by countries or regions, and specific standard requirements may vary from country to country or region. Therefore, when developing electronic products, corresponding EMC test plans should be formulated according to different market demands and relevant regulations, and ensure that the products meet the corresponding EMC standard requirements to meet market access requirements.

[0069] In one embodiment, at least one of the multi-stage magnetic rings 51 is a nanocrystalline magnetic ring, and at least one of the multi-stage magnetic rings 51 is a ferrite magnetic ring. Specifically, in this embodiment, the first-stage magnetic ring is an annular nanocrystalline magnetic ring, and the second-stage magnetic ring and the third-stage magnetic ring are both annular ferrite magnetic rings. Using magnetic rings 51 of different materials can achieve better magnetic properties and meet the use requirements of the dual-motor controller under different working conditions.

[0070] It is worth mentioning that nanocrystalline magnetic rings have good high-frequency characteristics, lower coercivity and loss. Ferrite magnetic rings are made of nickel-zinc and manganese-zinc materials, and are used in high-frequency inductors, transformers, filters, etc. They are the most commonly used materials in radio; ferrite magnetic rings can be divided into manganese-zinc ferrite magnetic rings and nickel-zinc ferrite magnetic rings. Manganese-zinc ferrite has the characteristics of high magnetic permeability and high magnetic flux density, and has low loss characteristics at frequencies below 1MHz. Nickel-zinc ferrite has extremely high impedance, low magnetic permeability of less than a few hundred, and also produces low loss at frequencies above 1MHz.

[0071] It should be noted that the dual-motor controller in this embodiment is an 800V high-voltage platform dual-motor controller.

[0072] When assembling the dual motor controller of this embodiment, first, assemble the EMC filter component 5, weld and assemble the primary X capacitor, the primary Y capacitor combination, the secondary X capacitor, the secondary Y capacitor combination and the interface circuit board 55, and then assemble the terminal block 56, the input bus 541, the primary magnetic ring, the secondary magnetic ring, the tertiary magnetic ring, the output bus 542 and the interface circuit board 55 to complete the assembly of the EMC filter component 5; then, assemble the two drive module components 2, assemble the SIC module 22, the three-phase current sensor 23 and the three-phase bus component 24, and then weld and assemble the signal pins of the drive circuit board 21 and the SIC module 22, and complete the assembly of the two drive module components 2. Assemble; then, fix the EMC filter component 5 in the first shielding space of the shell 17, install the two drive module components 2 respectively corresponding to the two heat dissipation tanks 111, install the film capacitor 3 and the distribution module 4 in the shell 17, make the film capacitor 3 correspond to the U-shaped loop setting, electrically connect the first busbar component 32 of the film capacitor 3 with the output bus 542 of the EMC filter component 5, and electrically connect the two second busbar components 33 of the film capacitor 3 with the two drive module components 2 respectively, fix the control circuit board 7 in the shell 17, and make the low-voltage signal connector 8 on the control circuit board 7 be located in the second shielding space; finally, install the internal wiring harness and encapsulate the cover plate 18 on the shell 17.

[0073] Although the embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art may make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations are all within the scope defined by the appended claims.

Claims

1. A dual motor controller, characterized in that: include: Box body (1); Two drive module assemblies (2) are provided, and the two drive module assemblies (2) are arranged side by side in the horizontal direction inside the box body (1); A thin film capacitor (3) is arranged between the two driving module components (2) and is electrically connected to the two driving module components (2); A power distribution module (4) is arranged in the housing (1) and is electrically connected to the film capacitor (3). The power distribution module (4) has a power supply state and a charging state. In the power supply state, the power distribution module (4) outputs the current provided by the vehicle battery to the film capacitor (3) to the electrical equipment. In the charging state, the power distribution module (4) transmits the current of the external power supply to the vehicle battery via the film capacitor (3). An EMC filter component (5) is arranged in the housing (1) and is electrically connected to the film capacitor (3); the EMC filter component (5) has a power connection terminal, and the power connection terminal is suitable for connecting to a vehicle battery.

2. The dual motor controller according to claim 1, characterized in that: The thin-film capacitor (3) comprises a capacitor body (31), a first busbar assembly (32), a second busbar assembly (33) and a third busbar assembly (34); the first busbar assembly (32), the second busbar assembly (33) and the third busbar assembly (34) are all electrically connected to the capacitor body (31); the first busbar assembly (32) is electrically connected to the EMC filter assembly (5); two second busbar assemblies (33) are provided, and the two second busbar assemblies (33) are electrically connected to the two drive module assemblies (2) respectively; and the third busbar assembly (34) is electrically connected to the power distribution module (4).

3. The dual motor controller according to claim 1 or 2, characterized in that: A cooling channel is formed in the bottom plate (11) of the housing (1); a liquid inlet (12) and a liquid outlet (13) are provided on the housing (1); the liquid inlet (12) and the liquid outlet (13) are arranged through the housing (1) and are respectively connected to two ends of the cooling channel; the two drive module components (2) and the thin film capacitor (3) are both arranged on the bottom plate (11) and are arranged corresponding to the cooling channel.

4. The dual motor controller according to claim 3, characterized in that: The box body (1) further comprises a surrounding plate (14), the surrounding plate (14) being connected to the bottom plate (11) and being circumferentially arranged around the bottom plate (11), a first shielding plate (15) being protruding from the bottom plate (11), the first shielding plate (15) enclosing a first shielding space, or the first shielding plate (15) and the surrounding plate (14) enclosing a first shielding space; The EMC filter component (5) is arranged in the first shielding space, and the dual-motor controller further comprises an EMC shielding plate (6), wherein the EMC shielding plate (6) is arranged above the EMC filter component and closes the first shielding space.

5. The dual motor controller according to claim 4, characterized in that: A second shielding plate (16) is protruded from the bottom plate (11), and the second shielding plate (16) encloses a second shielding space, or the second shielding plate (16) and the enclosure plate (14) enclose a second shielding space; the dual-motor controller also includes a control circuit board (7) and a low-voltage signal connector (8), and the low-voltage signal connector (8) is arranged on the control circuit board (7) and is electrically connected to the control circuit board (7); the control circuit board (7) is stacked on top of the EMC shielding plate (6), and the portion of the low-voltage signal connector (8) protruding from the lower surface of the control circuit board (7) is located in the second shielding space, and the control circuit board (7) closes the second shielding space.

6. The dual motor controller according to claim 5, characterized in that: The driving module assembly (2) comprises a driving circuit board (21) and a SIC module (22), the driving circuit board (21) being electrically connected to the SIC module (22), the SIC module (22) being arranged above the bottom plate (11), the driving circuit board (21) being arranged above the SIC module (22), and the control circuit board (7) and the driving circuit board (21) being arranged flat in the same horizontal plane.

7. The dual motor controller according to claim 1 or 2, characterized in that: The EMC filter component (5) comprises: a plurality of filter subcircuits connected in series, each of the filter subcircuits comprising: an LC filter circuit, a plurality of first RC filter circuits and a plurality of second RC filter circuits, wherein: A first end of each of the first RC filter circuits is connected to a first end of the LC filter circuit, a second end of each of the first RC filter circuits is connected to a first end of each of the second RC filter circuits, and a second end of each of the second RC filter circuits is connected to a second end of the LC filter circuit; The LC filter circuit comprises a magnetic ring (51) and an X capacitor (52) connected in parallel; The first RC filter circuit and the second RC filter circuit both include a resistor and a Y capacitor combination (53) connected in series.

8. The dual motor controller according to claim 7, characterized in that: The EMC filter component (5) further comprises a busbar (54) and an interface circuit board (55); the multi-stage X capacitors (52) and the multi-stage Y capacitors are both connected to the interface circuit board (55); the busbar (54) passes through the multi-stage magnetic rings (51) in sequence; one end of the busbar (54) forms the power connection end; the other end of the busbar (54) is electrically connected to the film capacitor (3); the busbar (54) is connected to the interface circuit board (55) between two adjacent stages of the magnetic rings (51) through a copper busbar, and is connected to a corresponding one of the X capacitors (52) and one of the Y capacitors (53) through the interface circuit board (55).

9. The dual motor controller according to claim 8, characterized in that: At least one of the multiple levels of magnetic rings (51) is a nanocrystalline magnetic ring (51), and at least one of the multiple levels of magnetic rings (51) is a ferrite magnetic ring (51).

10. The dual motor controller according to claim 5, characterized in that: The dual-motor controller further comprises a low-voltage shielding cover (9), which is connected to the upper surface of the control circuit board (7) and covers the low-voltage signal connector (8).

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